U.S. patent application number 17/068752 was filed with the patent office on 2022-04-14 for renewable-based flexible polyurethane foams.
This patent application is currently assigned to Ford Global Technologies, LLC. The applicant listed for this patent is Ford Global Technologies, LLC. Invention is credited to Alper Kiziltas, Deborah Frances Mielewski.
Application Number | 20220112326 17/068752 |
Document ID | / |
Family ID | 1000005182545 |
Filed Date | 2022-04-14 |
United States Patent
Application |
20220112326 |
Kind Code |
A1 |
Kiziltas; Alper ; et
al. |
April 14, 2022 |
RENEWABLE-BASED FLEXIBLE POLYURETHANE FOAMS
Abstract
A polyurethane foam is produced by reacting a polyol-containing
composition and an isocyanate composition. The polyol-containing
composition includes a petrol-based polyol, an algae-based polyol,
and a soy-based polyol.
Inventors: |
Kiziltas; Alper; (Sarikamis,
TR) ; Mielewski; Deborah Frances; (Ann Arbor,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Assignee: |
Ford Global Technologies,
LLC
Dearborn
MI
|
Family ID: |
1000005182545 |
Appl. No.: |
17/068752 |
Filed: |
October 12, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08G 2110/0083 20210101;
C08G 18/14 20130101; C08G 18/3206 20130101; C08G 18/18 20130101;
C08J 9/125 20130101; C08J 2375/04 20130101; C08G 18/7685
20130101 |
International
Class: |
C08G 18/32 20060101
C08G018/32; C08G 18/76 20060101 C08G018/76; C08G 18/18 20060101
C08G018/18; C08G 18/08 20060101 C08G018/08; C08J 9/12 20060101
C08J009/12 |
Claims
1. A polyurethane foam produced by reacting a polyol-containing
composition and an isocyanate composition, wherein the
polyol-containing composition comprises: an algae-based polyol at
less than or equal to about 20 parts by weight percent; a
petrol-based polyol at greater than or equal to about 70 parts by
weight percent to less than or equal to about 90 parts by weight
percent; and a balance of a soy-based polyol.
2. The polyurethane foam of claim 1, wherein the polyurethane foam
further comprises at least one of a cell opener, a surfactant, a
cross-linking agent, a catalyst, and a water blowing agent.
3. The polyurethane foam of claim 1 further comprising: a cell
opener at about 1 parts by weight percent; a surfactant at about
0.5 parts by weight percent; a cross-linking agent is at about 1.5
parts by weight percent; a catalyst comprising a first catalyst at
about 0.6 parts by weight percent and a second catalyst at about
0.3 parts by weight percent; and a water blowing agent at about 3
parts by weight percent.
4. The polyurethane foam of claim 1, wherein the polyurethane foam
has a compression set of less than or equal to about 50%.
5. The polyurethane foam of claim 1, wherein the polyurethane foam
has a tensile strength of greater than or equal to about 100
kPa.
6. The polyurethane foam of claim 1, wherein the polyurethane foam
has a tear resistance of greater than or equal to about 450
N/m.
7. A vehicle component comprising the polyurethane foam of claim
1.
8. A polyurethane foam produced by reacting a polyol-containing
composition and an isocyanate composition, wherein the
polyol-containing composition comprises: a soy-based polyol at less
than or equal to about 20 parts by weight percent; a petrol-based
polyol at greater than or equal to about 70 parts by weight percent
to less than or equal to about 90 parts by weight percent; and a
balance of an algae-based polyol.
9. The polyurethane foam of claim 8, wherein the polyurethane foam
further comprises at least one of a cell opener, a surfactant, a
cross-linking agent, a catalyst, and a water blowing agent.
10. The polyurethane foam of claim 8 further comprising: a cell
opener at about 1 parts by weight percent; a surfactant s at about
0.5 parts by weight percent; a cross-linking agent is at about 1.5
parts by weight percent; a catalyst comprising a first catalyst at
about 0.6 parts by weight percent and a second catalyst at about
0.3 parts by weight percent; and a water blowing agent at about 3
parts by weight percent.
11. The polyurethane foam of claim 8, wherein the polyurethane foam
has a compression set of less than or equal to about 50%.
12. The polyurethane foam of claim 8, wherein the polyurethane foam
has a tensile strength of greater than or equal to about 100
kPa.
13. The polyurethane foam of claim 8, wherein the polyurethane foam
has a tear resistance of greater than or equal to about 450
N/m.
14. A vehicle component comprising the polyurethane foam of claim
8.
15. A polyurethane foam produced by reacting a polyol-containing
composition and an isocyanate composition, wherein the
polyol-containing composition comprises: a bio-based polyol
consisting essentially of a combination of a soy-based polyol and
an algae-based polyol at less than or equal to about 80 parts by
weight percent; and a balance of a petrol-based polyol.
16. The polyurethane foam of claim 15, wherein the bio-based polyol
is less than or equal to about 80 parts by weight percent.
17. The polyurethane foam of claim 15, wherein the polyurethane
foam further comprises at least one of a cell opener, a surfactant,
a cross-linking agent, a catalyst, and a water blowing agent.
18. The polyurethane foam of claim 15 further comprising: a cell
opener at about 1 parts by weight percent; a surfactant s at about
0.5 parts by weight percent; a cross-linking agent is at about 1.5
parts by weight percent; a catalyst comprising a first catalyst at
about 0.6 parts by weight percent and a second catalyst at about
0.3 parts by weight percent; and a water blowing agent at about 3
parts by weight percent.
19. A vehicle component comprising the polyurethane foam of claim
15.
20. The polyurethane foam of claim 15, wherein the isocyanate
composition is greater than or equal to about 33 parts by weight
percent to less than or equal to about 40 parts by weight percent.
Description
FIELD
[0001] The present disclosure relates to sustainable polyurethane
foams.
BACKGROUND
[0002] The statements in this section merely provide background
information related to the present disclosure and may not
constitute prior art.
[0003] Conventional methods for developing polyurethane foams
typically include reacting a mixture with at least one polyol with
hydroxyl groups (such as petroleum-based polyols) with a mixture
having at least one isocyanate and/or diisocyanates in the presence
of additives, such as blowing agents, surfactants, and catalysts by
forming a gas (e.g., carbon dioxide) while urethane polymerization
occurs (the mixture of the polyol mixture, the isocyanate mixture,
and additives is also referred to as a reaction mixture). The gas
is formed as a result of the blowing agent, which typically is
water, reacting with the isocyanates, thereby forming carbon
dioxide and polyurea.
[0004] Such polyurethane foams are used in a variety of automotive
applications, as they can form lightweight, flexible,
high-resilience, and rigid foams. It has been observed that
bio-based (such as soy-based) polyols can be substituted for a
small amount of the petroleum-based polyol, e.g., in an amount of
up to about 12 parts by weight percent depending on the
application, but greater concentrations of bio-based polyols
greatly decrease mechanical and physical properties.
[0005] These issues related to the design of renewable-based
polyurethane foams, particularly in automotive applications, are
addressed by the present disclosure.
SUMMARY
[0006] This section provides a general summary of the disclosure
and is not a comprehensive disclosure of its full scope or all of
its features.
[0007] In one form of the present disclosure, a polyurethane foam
is produced by reacting a polyol-containing composition and an
isocyanate composition. The polyol-containing composition includes
an algae-based polyol at less than or equal to about 20 parts by
weight percent, a petrol-based polyol at greater than or equal to
about 70 parts by weight percent to less than or equal to about 90
parts by weight percent, and a balance of a soy-based polyol.
Variations of the present disclosure are set forth below, which may
be implemented individually or in any combination.
[0008] In a variation, the polyurethane foam further includes at
least one of a cell opener, a surfactant, a cross-linking agent, a
catalyst, and a water blowing agent. In a further variation, the
cell opener is at about 1 parts by weight percent; the surfactant
is at about 0.5 parts by weight percent; the cross-linking agent is
at about 1.5 parts by weight percent; the catalyst includes a first
catalyst at about 0.6 parts by weight percent and a second catalyst
at about 0.3 parts by weight percent; and the water blowing agent
is at about 3 parts by weight percent.
[0009] In another variation, the polyurethane foam has a
compression set of less than or equal to about 50%.
[0010] In a further variation, the polyurethane foam has a tensile
strength of greater than or equal to about 100 kPa.
[0011] In a further still variation, the polyurethane foam has a
tear resistance of greater than or equal to about 450 N/m.
[0012] In a yet further variation, a vehicle component is formed of
the polyurethane foam.
[0013] In another form of the present disclosure, a polyurethane
foam is produced by reacting a polyol-containing composition and an
isocyanate composition. The polyol-containing composition includes
a soy-based polyol at less than or equal to about 20 parts by
weight percent, a petrol-based polyol at greater than or equal to
about 70 parts by weight to less than or equal to about 90 parts by
weight percent, and a balance of an algae-based polyol.
[0014] In another variation, the polyurethane foam further includes
at least one of a cell opener, a surfactant, a cross-linking agent,
a catalyst, and a water blowing agent. In a further variation, the
cell opener is at about 1 parts by weight percent; the surfactant
is at about 0.5 parts by weight percent; the cross-linking agent is
at about 1.5 parts by weight percent; the catalyst includes a first
catalyst at about 0.6 parts by weight percent and a second catalyst
at about 0.3 parts by weight percent; and the water blowing agent
is at about 3 parts by weight percent.
[0015] In another variation, the polyurethane foam has a
compression set of less than or equal to about 50%.
[0016] In a further variation, the polyurethane foam has a tensile
strength of greater than or equal to about 100 kPa.
[0017] In a further still variation, the polyurethane foam has a
tear resistance of greater than or equal to about 450 N/m.
[0018] In a yet further variation, a vehicle component is formed of
the polyurethane foam.
[0019] In a still further form, a polyurethane foam is produced by
reacting a polyol-containing composition and an isocyanate
composition. The polyol-containing composition includes a bio-based
polyol consisting essentially of a combination of a soy-based
polyol and an algae-based polyol at less than or equal to about 80
parts by weight percent and a balance of a petrol-based polyol.
[0020] In a variation, the bio-based polyol is at less than or
equal to about 80 parts by weight percent.
[0021] In another variation, the polyurethane foam further includes
at least one of a cell opener, a surfactant, a cross-linking agent,
a catalyst, and a water blowing agent. In a further variation, the
cell opener is at about 1 parts by weight percent; the surfactant
is at about 0.5 parts by weight percent; the cross-linking agent is
at about 1.5 parts by weight percent; the catalyst includes a first
catalyst at about 0.6 parts by weight percent and a second catalyst
at about 0.3 parts by weight percent; and the water blowing agent
is at about 3 parts by weight percent.
[0022] In a yet further variation, a vehicle component is formed of
the polyurethane foam.
[0023] In a still further variation, the isocyanate is greater than
or equal to about 33 parts by weight percent to less than or equal
to about 40 parts by weight percent.
[0024] Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
DETAILED DESCRIPTION
[0025] The following description is merely exemplary in nature and
is not intended to limit the present disclosure, application, or
uses. It should be understood that throughout the drawings,
corresponding reference numerals indicate like or corresponding
parts and features.
[0026] As used herein, "isocyanates" include diisocyanates such as
aromatic diisocyanates, toluene diisocyanates ("TDI"), and
methylene diphenyl diisocyanates ("MDI"), as well as
polyisocyanates, and mixtures thereof. Non-limiting examples of
isocyanates include methylene diphenyl diisocyanate (MDI), toluene
diisocyanate (TDI), hexamethylene diisocyanate (HDI), isophorone
diisocyanate (IPDI), 4,4'-diisocyanatodicyclohexylmethane (H12MDI),
1,5-naphthalenediisocyanate (NDI), tetramethyllxylenediisocyanate
(TMXDI), p-phenylenediisocyanate (PPDI), 1,4-cyclohexane
diisocyanate (CDI), tolidine diisocyanate (TODI), and combinations
thereof. It is contemplated isocyanates may include polymeric
materials.
[0027] As used herein, "petrol-based polyols" are polyether polyols
which can be used in the practice of the present disclosure and are
well known and widely available commercially. Such polyols are
generally at least about 80% by weight or more of a composition or
blend of compositions directly or indirectly obtained from a
non-renewable resource such as crude oil. In other embodiments, the
polyols are generally at least about 85% by weight, at least 90% by
weight, and/or at least 95% by weight or more of a composition or
blend of compositions directly or indirectly obtained from a
non-renewable resource such as crude oil. Non-limiting examples of
the polyether polyols include polyoxyethylene glycol,
polyoxypropylene glycol, polyoxybutylene glycol, polytetramethylene
glycol, block copolymers, for example, combinations of
polyoxypropylene and polyoxyethylene glycols, poly-1,2-oxybutylene
and polyoxyethylene glycols, poly-1,4-tetramethylene and
polyoxyethylene glycols, and random and block copolymer glycols
prepared from blends or sequential addition of two or more alkylene
oxides. The mechanical properties of the resultant polyurethane
foam may dictate the consistency of the polyol. More specifically,
higher molecular weight polyols generally form more flexible
polyurethanes, whereas lower molecular weight polyols generally
form more rigid polyurethanes.
[0028] As used herein, "bio-based polyols" refer to polyols
generally at least about 80% by weigh or more of a composition or
blend of compositions directly or indirectly obtained from a
natural oil. In other embodiments, the polyols are generally at
least about 85% by weight, at least 90% by weight, and/or at least
95% by weight or more of a composition or blend of compositions
directly or indirectly obtained from a natural oil. Natural oil, as
used herein, includes but is not limited to vegetable oils, animal
fats, tall oils, derivatives of these oils, combinations of any of
these oils, and the like. Representative non-limiting examples of
vegetable oils include canola oil, rapeseed oil, coconut oil, corn
oil, cottonseed oil, olive oil, palm oil, peanut oil, safflower
oil, sesame oil, soybean oil, sunflower oil, linseed oil, palm
kernel oil, tung oil, jatropha oil, mustard oil, pennycress oil,
carnellina oil, and castor oil. Representative non-limiting
examples of animal fats include lard, tallow, poultry fat, yellow
grease, and fish oil, as well as polyols made from the bio-based
diols 1,3-propanediol (PDO) and 1,4-butanediol (BDO) and diacids,
including succinic acid and larger acids such as Elevance's
Inherent C18 octadecanedioic acid (ODDA).
[0029] As used herein, "algae-based polyols" refer to polyols
generally at least about 80% by weigh or more of a composition or
blend of compositions directly or indirectly obtained from an algae
oil. In other embodiments, the polyols are generally at least about
85% by weight, at least 90% by weight, and/or at least 95% by
weight or more of a composition or blend of compositions directly
or indirectly obtained from a algae oil. Algae oil, as used herein,
includes but is not limited to microalgae, such as Nannochloropsis,
Spirulina, Chlorella; algae, such as red algae-Rhodophyta, red
algae, Pithophora oedegonia, green algae, among others, and
combinations thereof.
[0030] As noted above, polyurethane foams are typically prepared by
reacting isocyanates with polyols in the presence of additives. In
such a manner, it is contemplated that a polyol solution according
to the present disclosure includes at least a petrol-based polyol,
a bio-based polyol, an algae-based polyol, and any desired
additives. Such additives, some of which may be optional, include
at least one of a cell opener, a surfactant, a cross-linking agent,
a catalyst, and a water blowing agent. It is also contemplated that
a polyol solution may include a petrol-based polyol, a bio-based
polyol, cellulose reinforcements, and any desired additives.
[0031] Blowing agents assist in preparing foam, and water is a
desirable blowing agent. Other blowing agents suitable according to
the present disclosure include fluorocarbons, hydrochlorocarbons,
chorofluorocarbons, hydrofluorocarbons, hydrocarbons. It is also
contemplated that gas may be added directly to the polyol
isocyanate reaction mixture to form the foam.
[0032] Surfactants are useful for cell nucleation and cell opening
in foam applications and offer foam stabilization. One desirable
surfactant is TEGOSTAB.RTM. B 4690, available from Evonik Degussa,
but it is contemplated other nonionic surfactants may be suitable
for preparing the polyurethane foams disclosed herein.
[0033] Cross-linking agents may be used to control flexural and
other properties of the foam. Suitable cross-linking agents include
diethanolamine (DEA) and triethanolamine, which, when used in foam
applications, build firmness and increase catalytic activity.
[0034] Catalysts enhance the processing characteristics and
physical properties of polyurethane foams by promoting the basic
chemical reactions between polyol and isocyanate, reactions between
water and isocyanate, and reactions to trimerizate isocyanates.
Catalysts may be selected according to the needs of a particular
application, for example, to improve the polyether foaming process
of a wide variety of foams, including high-density unfilled foam,
filled foam, high load-bearing flexible foam, low-density foam, and
high resilience molded foam. Other catalysts may be selected to
delay the foam-forming reaction process, which can result in more
open foam structures. Suitable catalysts according to the present
disclosure are diluted amine ethers, such as NIAX.RTM. A300 and
liquid, water-soluble tertiary amines, such as NIAX.RTM. A-300,
each of which are available from Momentive Performance Materials.
Tertiary amines may be desirable as catalysts when water is present
in the polyol isocyanate reaction mixture, as it catalyzes the
isocyanate to react with water to form urea linkages with urethane.
According to a form, the catalyst may comprise a first catalyst
comprised of a diluted amine ether, and a second catalyst comprised
of a water-soluble tertiary amine.
[0035] Cell openers may be used to prepare foam structures that
have predominantly open cells, which gives it a larger value of air
permeability and include water-soluble emulsifiers, such as
LUMULSE.RTM. POE (26) GLYC, available from Vantage Specialty
Chemicals, Inc.
[0036] Other optional additives include buffers, dendritic
macromolecules, inorganic particulates, other types of polyols not
listed herein, polyisocyanates, flame retardants, deodorants,
colorants, fillers, combinations thereof, and other additives known
to those familiar with the technology.
[0037] Algae-Based Polyurethane Foams
[0038] Various polyol-based foam compositions including
petrol-based, soy-based, and algae-based foam compositions shown
below in Table 1 were prepared and tested according to the
teachings of the present disclosure.
TABLE-US-00001 TABLE 1 Example/Test Compositions of Petrol and
Bio-Based Polyurethane Foams in Parts by Weight Percent Agrol A 56
Algae 150 Rubinate Voranol AO Soy Algae 7304 Sample 4701 Polyol
Polyol Isocyanate 1 100.0 0.0 0.0 53.8 2 90.0 0.0 10.0 54.3 3 80.0
0.0 20.0 54.8 4 70.0 0.0 30.0 55.4 5 50.0 0.0 50.0 56.4 6 90.0 10.0
0.0 54.3 7 80.0 10.0 10.0 54.8 8 70.0 10.0 20.0 55.3 9 60.0 10.0
30.0 55.8 10 40.0 10.0 50.0 56.8 11 80.0 20.0 0.0 54.6 12 70.0 20.0
10.0 55.2 13 60.0 20.0 20.0 55.7 14 50.0 20.0 30.0 56.2 15 30.0
20.0 50.0 57.2 16 70.0 30.0 0.0 55.1 17 60.0 30.0 10.0 55.7 18 50.0
30.0 20.0 56.2 19 40.0 30.0 30.0 56.7 20 20.0 30.0 50.0 57.7 21
50.0 50.0 0.0 56.0 22 40.0 50.0 10.0 56.5 23 30.0 50.0 20.0 57.0 24
20.0 50.0 30.0 57.5
[0039] The working examples were produced according to the
following procedure. First, a polyol mixture was formed by mixing
together up to about 100 parts by weight percent petrol-polyol
(e.g., VORANOL.RTM. 4701, available from Dow Chemical Co.), about 1
parts by weight percent cell opener (e.g., LUMULSE.RTM. POE (26)
GLYC available from Lambent Corporation), about 0.5 parts by weight
percent surfactant (e.g., TEGOSTAB.RTM. B4690, available from
Evonik Nutrition & Care GmbH), about 1.5 parts by weight
percent cross-linking agent (e.g., DEA), about 0.3 parts by weight
percent of a first catalyst (e.g., NIAX.RTM. A1, available from
Momentive Performance Materials) and about 0.6 parts by weight of a
second catalyst (e.g., NIAX.RTM. A300, also available from
Momentive Performance Materials), about 3 parts by weight percent
blowing agent (e.g., deionized water), and, optionally, up to about
50 parts by weight percent soy-based polyol (e.g., AGROL.RTM. A 56
AO, available from BioBased Chemicals, LLC), and, optionally, up to
about 50 parts by weight percent algae-based polyol (e.g., Algae
150 algae polyol, available from Algenesis Materials) were added
with a handheld mixer at 1500 rpm for a five minutes. An isocyanate
(e.g., RUBINATE.RTM. 7304, available from Huntsman International
LLC) was added to the polyol mixture and mixed with the mixer for
12 seconds. The reaction mixture was poured into a closed mold
system that had been coated with Chem-Trend PU-11331 release agent
and warmed in a pre-heated oven at 65.degree. C. for 15 minutes.
Each foam was able to rise within the mold and demolding time was 6
minutes and upon release from the mold, was crushed by hand to
release trapped gases. Each foam was placed in a pre-heated oven at
65.degree. C. for 30 minutes and subsequently removed from the oven
and then at room temperature for a minimum of 12 hours to allow for
proper curing.
[0040] The resultant foams of the working examples shown in Table 1
had their apparent density tested according to ASTM 3574-08, Test
A; their compression force deflection tested according to ASTM
3574-08, Test C; their wet compression tested according to ASTM
3574-08, Test L; their tensile strength at break tested according
to ASTM 3574-08, Test E; their elongation at max load tested
according to ASTM 3574-08, Test E; and their test strength tested
according to ASTM D 624, Die C. SAG factor values of the foams were
also calculated from compression stress values. Three samples were
measured for each test and the results were averaged. Table 2 below
shows the results of the respective tests. (Parentheticals
represent standard deviation).
TABLE-US-00002 TABLE 2 Mechanical Properties of Compositions Formed
According to Table 1 Wet Compression Maximum Tensile Elongation
Density Set Compression Modulus Strength at maximum load Young's
Modulus Sample (kg/m.sup.3) (% Compression) (MPa) (kPa) (mm) (kPa)
1 47.2 (0.9) 21.1 (3.2) 0.056 (0.004) 114.6 (10.1) 88.4 (8.5) 194.0
(12.9) 2 48.5 (1.0) 32.5 (4.0) 0.056 (0.004) 128.8 (5.6) 100.8
(3.2) 182.2 (12.0) 3 47.7 (0.9) 35.8 (2.3) 0.084 (0.004) 139.4
(7.4) 100.7 (3.6) 209.1 (5.4) 4 47.7 (0.8) 38.6 (1.4) 0.085 (0.004)
142.0 (7.5) 89.6 (4.1) 237.8 (21.5) 5 48.0 (0.3) 46.3 (1.1) 0.160
(0.014) 145.9 (7.9) 78.6 (4.7) 499.7 (49.5) 6 47.6 (0.3) 27.6 (2.5)
0.069 (0.003) 107.0 (6.8) 94.2 (4.2) 170.7 (13.7) 7 50.4 (1.3) 33.7
(1.1) 0.071 (0.005) 137.0 (8.0) 101.4 (7.7) 211.1 (18.9) 8 49.8
(1.0) 38.1 (1.0) 0.090 (0.004) 151.7 (10.4) 102.9 (6.7) 248.5
(20.6) 9 48.7 (2.6) 41.4 (1.7) 0.103 (0.007) 128.0 (9.7) 88.2 (6.9)
251.6 (20.6) 10 52.5 (1.5) 44.6 (1.2) 0.199 (0.009) 142.6 (7.1)
77.0 (4.0) 372.8 (32.3) 11 50.3 (1.4) 29.8 (1.9) 0.084 (0.008)
140.1 (14.4) 100.4 (6.4) 208.6 (19.0) 12 51.3 (1.0) 34.6 (1.7)
0.074 (0.005) 145.9 (12.2) 97.2 (7.1) 255.2 (20.1) 13 48.4 (1.3)
40.1 (1.7) 0.107 (0.009) 126.9 (6.5) 88.8 (4.9) 260.5 (15.5) 14
48.9 (0.6) 42.3 (1.0) 0.121 (0.005) 142.6 (6.3) 84.7 (1.4) 335.2
(32.3) 15 47.6 (0.7) 47.3 (1.1) 0.162 (0.008) 134.7 (2.8) 63.9
(1.9) 442.8 (18.3) 16 43.8 (1.8) 41.7 (1.3) 0.074 (0.005) 109.8
(8.4) 88.6 (6.5) 184.4 (12.0) 17 43.5 (0.6) 46.0 (1.0) 0.096
(0.002) 126.9 (2.7) 91.7 (3.5) 218.8 (15.7) 18 44.3 1.2) 48.6 (0.3)
0.126 (0.009) 105.0 (11.9) 77.2 (6.9) 239.4 (15.1) 19 44.0 (0.7)
50.4 (1.2) 0.143 (0.008) 121.1 (5.1) 70.2 (2.2) 324.2 (8.7) 20 49.5
(0.9) 46.1 (1.0) 0.177 (0.009) 92.8 (4.7) 42.2 (3.6) 429.7 (37.0)
21 49.4 (0.6) 36.0 (1.9) 0.096 (0.007) 110.1 (6.8) 78.4 (4.6) 246.5
(21.1) 22 46.9 (2.2) 39.5 (2.3) 0.107 (0.007) 116.1 (8.4) 66.7
(4.2) 339.9 (28.3) 23 47.1 (3.0) 43.1 (1.3) 0.117 (0.009) 106.1
(8.8) 61.5 (4.5) 353.2 (28.9) 24 51.6 (1.1) 45.3 (0.8) 0.157
(0.008) 98.6 (7.9) 47.8 (2.7) 372.1 (32.1) Compression Compression
Compression Stress at 25% Strain Stress at 50% Strain Stress at 65%
Strain SAG Factor SAG Factor Tear Resistance Sample (MPa) (MPa)
(MPa) 65%/25% 50%/25% (N/m) 1 0.0049 (0.0002) 0.0074 (0.0002)
0.0122 (0.0004) 2.50 (0.10) 1.52 (0.02) 475.1 (34.4) 2 0.0050
(0.0003) 0.0076 (0.0003) 0.0124 (0.0004) 2.50 (0.14) 1.53 (0.04)
539.7 (36.9) 3 0.0074 (0.0006) 0.0110 (0.0007) 0.0182 (0.0010) 2.47
(0.10) 1.50 (0.03) 565.4 (31.2) 4 0.0089 (0.0004) 0.0125 (0.0006)
0.0196 (0.0010) 2.19 (0.04) 1.39 (0.02) 575.5 (10.5) 5 0.0193
(0.0012) 0.0255 (0.0013) 0.0390 (0.0017) 2.03 (0.12) 1.32 (0.04)
640.9 (27.9) 6 0.0057 (0.0005) 0.0088 (0.0007) 0.0147 (0.0008) 2.60
(0.11) 1.54 (0.02) 406.1 (37.1) 7 0.0063 (0.0005) 0.0092 (0.0006)
0.0152 (0.0009) 2.43 (0.10) 1.47 (0.03) 448.8 (30.9) 8 0.0080
(0.0003) 0.0119 (0.0003) 0.0194 (0.0006) 2.42 (0.09) 1.48 (0.03)
543.6 (21.4) 9 0.0096 (0.0002) 0.0139 (0.0005) 0.0226 (0.0011) 2.36
(0.09) 1.45 (0.03) 554.7 (23.2) 10 0.0186 (0.0006) 0.0263 (0.0006)
0.0430 (0.0011) 2.31 (0.07) 1.41 (0.03) 601.5 (11.2) 11 0.0082
(0.0006) 0.0125 (0.0006) 0.0120 (0.0009) 2.44 (0.15) 1.53 (0.06)
533.7 (18.3) 12 0.0071 (0.0004) 0.0105 (0.0005) 0.0169 (0.0008)
2.37 (0.10) 1.47 (0.03) 492.3 (45.1) 13 0.0106 (0.0005) 0.0153
(0.0008) 0.0245 (0.0014) 2.32 (0.06) 1.45 (0.03) 551.0 (26.0) 14
0.0104 (0.0003) 0.0153 (0.0003) 0.0254 (0.0006) 2.45 (0.07) 1.47
(0.03) 520.3 (27.1) 15 0.0221 (0.0009) 0.0283 (0.0008) 0.0420
(0.0012) 1.90 (0.08) 1.28 (0.03) 503.5 (18.7) 16 0.0067 (0.0003)
0.0099 (0.0006) 0.0163 (0.0010) 2.44 (0.09) 1.49 (0.03) 430.3
(35.4) 17 0.0081 (0.0004) 0.0122 (0.0006) 0.0204 (0.0006) 2.52
(0.07) 1.52 (0.02) 472.7 (29.0) 18 0.0105 (0.0007) 0.0158 (0.0011)
0.0264 (0.0019) 2.51 (0.06) 1.50 (0.02) 478.7 (18.7) 19 0.0134
(0.0008) 0.0190 (0.0010) 0.0310 (0.0014) 2.31 (0.09) 1.41 (0.03)
598.4 (20.7) 20 0.0233 (0.0004) 0.0304 (0.0010) 0.0451 (0.0015)
1.93 (0.06) 1.31 (0.03) 433.2 (33.7) 21 0.0087 (0.0005) 0.0131
(0.0006) 0.0213 (0.0011) 2.45 (0.08) 1.51 (0.04) 454.6 (39.3) 22
0.0098 (0.0003) 0.0143 (0.0004) 0.0233 (0.0008) 2.39 (0.08) 1.46
(0.02) 545.7 (20.8) 23 0.0117 (0.0003) 0.0164 (0.0005) 0.0263
(0.0009) 2.25 (0.08) 1.41 (0.02) 463.2 (20.3) 24 0.0185 (0.0015)
0.0254 (0.0011) 0.0384 (0.0016) 2.09 (0.09) 1.38 (0.06) 431.4
(29.6)
[0041] The results and data presented in Table 2 demonstrate that
polyurethane foam produced from petrol-based polyol compositions
including algae-based polyols offset mechanical deficiencies
expected from petrol-based polyol compositions including soy-based
polyols. More specifically, as shown in Table 2, small amounts of
algae content (e.g., below about 20 parts by weight percent)
resulted in polyurethane foams having increased wet compression
set, compression strength, compression stress at 25, 50, and 65%
strain, Young's modulus, and tear resistance.
[0042] The polyurethane foams disclosed hereunder may be used in
various applications where it is desirable to have foams having the
properties disclosed hereunder. Further, the polyurethane foams
disclosed hereunder may be used in various automotive applications
and for vehicle components, including but not limited to seat
backs, seat cushions, headrests, armrests, headliners, engine
covers, and instrument panels.
[0043] Unless otherwise expressly indicated herein, all numerical
values indicating mechanical/thermal properties, compositional
percentages, dimensions and/or tolerances, or other characteristics
are to be understood as modified by the word "about" or
"approximately" in describing the scope of the present disclosure.
This modification is desired for various reasons including
industrial practice, material, manufacturing, and assembly
tolerances, and testing capability.
[0044] Although the terms first, second, third, etc. may be used to
describe various elements, components, regions, layers and/or
sections, these elements, components, regions, layers and/or
sections, should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer
and/or section, from another element, component, region, layer
and/or section. Terms such as "first," "second," and other
numerical terms when used herein do not imply a sequence or order
unless clearly indicated by the context. Thus, a first element,
component, region, layer or section, could be termed a second
element, component, region, layer or section without departing from
the teachings of the example forms. Furthermore, an element,
component, region, layer or section may be termed a "second"
element, component, region, layer or section, without the need for
an element, component, region, layer or section termed a "first"
element, component, region, layer or section.
[0045] Spacially relative terms, such as "inner," "outer,"
"beneath," "below," "lower," "above," "upper," and the like, may be
used herein for ease of description to describe one element or
feature's relationship to another element(s) or feature(s) as
illustrated in the figures. Spatially relative terms may be
intended to encompass different orientations of the device in use
or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or
features would then be oriented "above" the other elements or
features. Thus, the example term "below" can encompass both an
orientation of above or below. The device may be otherwise oriented
(rotated 90 degrees or at other orientations) and the spatially
relative descriptors used herein interpreted accordingly.
[0046] As used herein, the phrase at least one of A, B, and C
should be construed to mean a logical (A OR B OR C), using a
non-exclusive logical OR, and should not be construed to mean "at
least one of A, at least one of B, and at least one of C."
[0047] The description of the disclosure is merely exemplary in
nature and, thus, variations that do not depart from the substance
of the disclosure are intended to be within the scope of the
disclosure. Such variations are not to be regarded as a departure
from the spirit and scope of the disclosure.
* * * * *